Novexx Solutions ALS 104 User manual

Edition 2 - 1/2016 - Translation of original version
INSTALLATION MANUAL
ALS 104
Labeler

Installation Manual ALS 104
01/2016 3Contents
Contents
Please observe the following -5
General information -5
Validity and applicability of this manual -5
Conventions and information -6
Notes on installation and repair work -7
Safety instructions -10
Information and qualifications -10
Machine operating safety -11
Safe operation -12
Installation and Deinstallation -14
Dimension diagrams -14
Unpacking, assembling and connecting the machine -16
Transport -16
Unpacking -16
Setting up -17
Attaching the dispensing edge -21
Connecting to the mains power supply -23
Connecting / mounting the external operator panel -26
Connecting the sensors -28
Label sensor -28
Capacitive label sensor (option) -31
Product sensor -34
Roll diameter sensor -35
Rotary encoder -38
Decommissioning, Dismantling, Disposal -40
Take the machine out of operation -40
Dismantling the machine -40
Machine disposal -40

Installation Manual ALS 104
01/2016 4Contents

Installation Manual ALS 104
01/2016 | 00 5Please observe the following
Please observe the following
GENERAL INFORMATION
Validity and applicability of this manual
Contents
The complete operating manual for the ALS 104 label dispenser consists of the following parts:
1) Only for certified and qualified service technicians or OEM partners.
The present installation manual refers exclusively to the ALS104 label dispenser. It is to be referred
to for correct installation, set-up and adjustment of the label dispenser.
Technical State
Technical state: 01/2007
Firmware: 3.21(Frontend), 1.85 R02 (Drive)
Liability
NOVEXX Solutions assumes no liability for damages resulting from improper adjustments or
repairs of the machine. It is assumed that only knowledgeable and appropriately qualified persons
are to perform installation, adjustment, or repairs.
Information about the required qualification: see chapter Information and qualifications on
page 10.
Copyright notice
All rights to this operating manual are assigned to NOVEXX Solutions. Transmission, reprinting or
any other means of reproduction of this manual, whether whole or in part, are not allowed without
prior written permission. Third parties, in particular competitors, are not to be allowed access to
information derived from this manual.
Printed in Germany
Manufacturer
Novexx Solutions GmbH
Ohmstraße 3
D - 85386 Eching
Phone: [phone]
FAX: [phone]
www.novexx.com
Manual Target group Medium Availability
User manual Operating personnel Printed Comes with machine
Installation manual Service personnel User Docu-CD
Service manual Service Docu-CD Must be ordered
separately1
Spare parts catalogue

Installation Manual ALS 104
01/2016 | 00 6Please observe the following
Conventions and information
Explanation of symbols
In order to facilitate legibility and an overview, the various types of information used herein are cat-
egorised and identified with certain symbols.
Sentences that are introduced by an arrow contain procedural instructions.
Carry out procedural instructions one after the other in the prescribed order.
The following information is introduced with a dash:
– List items
– Descriptions of conditions
– Description of previous work steps
– Prerequisites for implementing actions described in the following passage
Warnings concerning dangers and risks
Important text passages which must absolutely be followed are particularly marked for special
attention:
Illustrations
When required, text passages are accompanied by illustrations. The reference to an illustration is
indicated by typesetting the [illustration number] in square brackets. Capital letters following an
illustration number, e.g. [12A], refer to the corresponding position indicated in the illustration.
Symbols for keys
– Keys on the operator panel are represented with symbols
– Where two or more keys must be pressed at the same time, a "+" appears between the symbols:
+
Functions
Functions are printed in grey text, in the form NAME OF MENU > Name of function .
Supplemental information
The information symbol indicates notices and recommendations as well as additional helpful
information.
Auxiliary materials:
– Auxiliary materials, e.g. lubricants, glues or cleaning agents
WARNING!
A warning notice indicates risks which could result in death or serious injury of the personnel!
The notice contains safety instructions on how to safeguard possibly affected personnel.
The instructions must be followed.
CAUTION!
A caution notice indicates risks which, if unheeded, could lead to material damage or
bodily injury (minor injuries). The notice contains instructions on how to prevent dam-
age or injury.
The instructions must be followed.

Installation Manual ALS 104
01/2016 | 00 7Please observe the following
Tightening torques:
– Tightening torques for the listed screw connections
If special tools or other aids are needed for a task:
Tools:
– List of the tools and aids that are required for the following activities
Notes on installation and repair work
General information
Before performing any maintenance or repair work:
Block access to the working area of the machine to unauthorised persons.
Post a notification sign, which calls attention to the work.
Electro-static discharge:
When the casing is open, protect the electronics from damage due to electro-static discharge,
e.g. wear an anti-static arm band.
Tools:
Only use suitable tools.
Ensure all tools are at hand before beginning the work.
Do not attempt to improvise or to use improper tools, e.g. loosening an interior-toothed screw
(Torx) with a hexagon socket driver.
Rubber and plastic parts:
Do not allow hoses, seals, and other rubber or plastic parts to come into contact with grease,
petrol, benzene, kerosene or mineral oil.
Environmental protection
Avoid unnecessary waste, e.g. use cleaning cloths sparingly and reuse packing material.
Only store operating materials, such as fresh or used cleaning agents, in suitable containers.
Never allow them to enter the sewerage system or to seep into the ground.
Do not put old batteries, removed parts, and used cleaning agents in household waste. Dispose
of them in an eco-friendly manner.
Packaging materials:
– Only recyclable materials are used for packaging the machine.
Dispose of unwanted packaging material in an eco-friendly manner.
Eco-friendly disposal:
Sort the waste as much as possible, e.g. separate metals from plastics.
Avoid contaminating the waste if possible.
Drop off the waste at the collection points provided for that purpose
or
Have the waste collected by suitable recycling agencies.
Use any on-site options.
Observe all relevant rules, ordinances, and laws.

Installation Manual ALS 104
01/2016 | 00 8Please observe the following
Rules for electromagnetic compatibility
Connect all metallic parts to each other via large surfaces, ensuring electric conductivity.
– Only polished metal surfaces are electrically conductive. Painted or oxidised surfaces are unsui-
table. Aluminium which appears to be polished still has an invisible oxidation layer on the surfa-
ce.
– Coated or plated surfaces, though electrically conductive, can reach very high resistance values
at high frequencies (skin effect).
Clean contact surfaces, polish the metal, use fan disks (washers) or mounting plates.
Carry out EMC grounding, preferably as a neutral (star) point. A neutral (star) point prevents lo-
ops.
When laying the signal lines and power cable, space them apart.
Lay all control and signal lines at least 50 cm distant from power cables (e.g. motor line). Mini-
mum distance in the switch cabinet: 20 cm.
Spatially lay out all the lines in the switch cabinet as close as possible to the reference potential.
Lead the signal lines into the unit or switch cabinet from one side only.
– The more lines that are laid in front and in back between the switch cabinet and the machine,
the larger the radiation surface of the radiated electromagnetic energy.
Lead the signal lines out of the machine (in one bundle and from one location, if possible) and
into the switch cabinet.
Twist together unshielded lines from the same circuit.
– This reduces interference effects of various kinds.
Wire inductive components to suitable interference suppressors.
– Possible inductive components: Relay, solenoid valve
– Possible interference suppressors: Diodes, varistors, RC combinations
House all components suspected of being sources of RF interference fields in a closed metal
casing (Faraday screen).
Shield all signal and control lines.
Ground the shielding on both sides at its large surfaces.
For insufficient potential equalisation between the shielding lines: Lay an additional equalisation
lead parallel to the shielding with a cross section at least 10 mm2.
Avoid equalisation currents in the shielding of the signal lines
– Equalisation currents can arise between subassemblies with different grounding conditions.
When the grounding conditions are different, only shield the side with the better grounding con-
dition.
Only shield both sides when the grounding conditions are the same (e.g. inside a machine).

Installation Manual ALS 104
01/2016 | 00 9Please observe the following
Power filter
Mount the power filter direct at the power supply.
Connect the filter casing to the EMC grounding via large metal surfaces.
Lay all lines as close as possible to metal parts, even reserve cables
– Freely hanging lines act as transceiver antennas.
Ground all reserve cables and unused wires in the cables at least at one end.
Keep the cables as short as possible
– Cable resistance and signal distortion increase with the length of the cable.

Installation Manual ALS 104
01/2016 | 00 10 Please observe the following
SAFETY INSTRUCTIONS
Information and qualifications
Ensure necessary qualifications
Only allow appropriately qualified personnel to set up, adjust, and repair the labeler, e.g. me-
chanical and electronics specialists.
Only allow work on the electronics system to be done by authorised electronics technicians.
Clearly define the responsibilities for installing, setting up, adjusting, and repairing the labeler.
Consistently adhere to the responsibilities.
Qualification for system integrators and service technicians („service personnel“)
Knowledge required to install the print dispenser and perform service work must be demon-
strated through appropriate qualification. Only service personnel with technical training are
able to assess the tasks to be performed and recognise potential dangers.
– Knowledge acquired through technical training in mechanics and electronics (for example in
Germany the training to become a mechatronics engineer).
– Participation in a technical training course for the corresponding labeler offered by the manufac-
turer.
– The service personnel must be acquainted with the functionality of the labeler.
– The system integrator must be acquainted with the functionality of the of the system into which
the labeler is being integrated.
1) For example faults when detecting labels
2) For example incorrect labelling
Tasks System integrator Operator Service technician
Install the machine X
Connect X
Make settings X
Switch on/off X X X
Insert/change material/ribbon X X X
Application-related settings X X X
Rectify minor operating faults 1XX X
Clean the machine X X
Rectify major operating faults 2X
Settings to the electronics/ mechanics X
Repairs X
Manual: Service manual Operating Manual Service manual, spare
parts catalogue
[tab. 1]An example of the distribution of tasks among different qualified personnel

Installation Manual ALS 104
01/2016 | 00 11 Please observe the following
Pay attention to the information
1) Examples: Work place regulation, Accident prevention regulations, Trade union regulations for occupational safety and
health, Equipment safety law, Recycling and waste management law
Information must be made available
This service guide
must be made available to all persons who are entrusted with installing, setting up, adjusting, or
repairing the labeler.
must be maintained in legible condition.
must be made available to the new owner if the machine is sold.
Safety and warning notices attached to the labeler must be kept clean and legible. Missing or
damaged warning plates are to be replaced.
Machine operating safety
Installation, maintenance
WARNING!
Reliable and efficient operation of the labeler is only guaranteed if all necessary information is
observed!
Carry out the installation, connection, programming, setting, and repairing of the machine ex-
clusively in accordance with the specifications in this manual.
Observe additional safety and warning notices attached to the labeler.
Observe and adhere to all relevant ordinances and rules in their applicable form1.
WARNING!
Improper usage of the machine can lead to accidents, material damage and loss of production!
When installing the labeler, check for visible shipment damage. Immediately inform Novexx
Solutions of any damage.
When installing the machine on a support stand, make sure that it can not tip over.
Only put the labeler into operation if it is in flawless condition.
Only perform alterations or conversions to the labeler with the consent of Novexx Solutions's
customer service.
Only use original replacement parts.
Danger of body part trapping and pinching at the dispensing edge due to products moving in the
conveyor direction!
Take appropriate measures to prevent personnel from reaching between a product and the
dispensing edge; e.g. install a protective guard or shield.
Before starting up the machine:
Carry out test runs using the task-specific settings under near production conditions.
Only put the machine into operation after at least one successful test run has been complet-
ed.

Installation Manual ALS 104
01/2016 | 00 12 Please observe the following
After all servicing or repair work
Safe operation
Protect against injuries that can result from electrical current
WARNING!
Risk of an accident due to moving or loose parts!
Re-install all covers and safety equipment.
Check for firm seating of all screw connections that were loosened during the work.
Remove all tools and other aids used during service and repair from the working area of the
labeler.
Verify flawless functioning of all safety equipment.
This unit operates at mains voltage! Coming into contact with electrically live components can
cause potentially lethal electrical shocks and burns.
After assembling, check the printer according to the regulations relevant in your country.
WARNING!
Contact with energised components can result in life-endangering currents through the body as
well as burns. The labeler is connected with the mains supply!
Only allow work on the electronics system to be done by authorised electronics technicians.
Observe the following information unconditionally.
Power connection:
If the power switch is not accessible due to the installation position of the machine, a suitable
accessible separator has to be provided by the system integrator.
The device is only completely disconnected from the mains if the power cable is unplugged.
Make sure the power supply socket is accessible.
In case of emergency, switch off the device and disconnect the power cable.
(ALS 104 with splash guard) The power cable cannot be pulled off from the machine side power
connector .
If the machine is connected to a cabinet, a suitable and accessible power separator must be
provided by the system integrator.
Before any repair work:
Detach the machine from power supply.
Check to ensure it is de-energised.
Secure the power supply against unintentional or unauthorised switch-on.
Casing:
Before opening the casing pull the power plug.
The casing may only be opened by trained personnel and when the machine is de-energised.
Only put the machine into operation when the rear wall of the casing is correctly in place.

Installation Manual ALS 104
01/2016 | 00 13 Please observe the following
Protection against injuries that can result from mechanical actions
If the machine must be switched on while the casing is open for repair or inspection:
Never touch energised components. This also applies to components with low voltages.
Ensure the flawless condition of the electrical system:
Regularly check the electrical equipment.
Only connect the machine to other machines if these meet the requirements for a SELV cir-
cuit, in accordance with EN 60950.
Re-tighten loose connections.
Immediately replace damaged lines.
After assembling, check the printer according to the regulations relevant in your country.
WARNING!
Acute risk of injury and long-term bodily injury from working with heavy loads!
Lift or carry the machine with a minimum of 2 persons. If possible, use a crane or other lifting
device.
Only use suitable and defect-free restraining devices during transportation and installation.
Never allow the machine to stand with loosened mounting brackets, not even for a short time.
If the machine is fastened to a movable support: Ensure it can not tip over.
Risk of accident due to uncontrolled machine start-up!
Before doing any repair work, switch off the machine and pull the power plug.

Installation Manual ALS 104
01/2016 | 00 14 Installation and Deinstallation
Installation and Deinstallation
DIMENSION DIAGRAMS
[2] Dimensions of the ALS 104 - part 1
431
226
474
75 173
248
24
30
471
431
226
266
205
32
74
60
118
330 84
111
113
140
86
414
132

Installation Manual ALS 104
01/2016 | 00 15 Installation and Deinstallation
[3] Dimensions of the ALS 104 - part 2
341
492
488
205 320

Installation Manual ALS 104
01/2016 | 00 16 Installation and Deinstallation
UNPACKING, ASSEMBLING
AND CONNECTING THE
MACHINE
Transport
Unpacking
Lift the machine out of the packaging with at least
two persons.
– To do so, hold the machine by its casing.
After unpacking, check the machine for visible ship-
ment damage.
Alternatively, the machine can be lifted with a
crane.
To do so, screw an eye ring M10 into the
location shown in [4A].
CAUTION!
To avoid damaging the machine during
transport:
Only transport the machine in its orig-
inal packaging.
Keep the original packaging for a later
transport.
WARNING!
Acute risk of injury and long-term bodily
injury from working with heavy loads!
Lift or carry the machine with a mini-
mum of 2 persons. If possible, use a
crane or other lifting device.
CAUTION!
To avoid damaging the machine during
unpacking:
Never hold the machine by the deflec-
tion rollers, dancer arm or rewind or un-
wind unit.
[4] Attachment of an eye ring M10 (A) for transportation with a
crane.
A

Installation Manual ALS 104
01/2016 | 00 17 Installation and Deinstallation
Setting up
Prerequisites:
Support stand with a tube end providing the following
measures:
– Outer diameter: 60 mm
– Wall thickness: minimum 5 mm
The machines offer three attachment points for mount-
ing to the support:
– Rear side
Requires a fixing bolt to be mounted on the rear side
of the machine. A joint [5B] is used to attach the fi-
xing bolt to the support. Advantage: The machine
can be inclined both side to side and forwards and
backwards.
– Side plate
Requires a flange [5A] to be mounted on the side
wall of the machine.
– Base plate
Requires a flange [5C] to be mounted on the base of
the machine casing.
WARNING!
Risk of injury from a tipping over support
stand.
When installing the machine on a sup-
port stand, make sure that it can not tip
over.
Fix the support stand onto the ground.
[5] Attachment points
C
B
A

Installation Manual ALS 104
01/2016 | 00 18 Installation and Deinstallation
For machines held from the rear side
– Order number for fixing bolt assembly [6A] (inclu-
ding screw and cylinder pins): A7621
Tools:
– 17 mm hexagon socket driver
– 8 and 10 mm hexagon socket drivers
Locate the two cylinder pins [6B] in the holes in the
fixing bolt [6A].
Screw the fixing bolt [7B] onto the flange on the rear
side of the machine with the screw provided [7C].
– The two cylinder pins must locate into the holes [7A]
in the flange.
– Mount the fixing bolt with its bevelled side pointing
inwards towards the machine.
Tightening torque:350 Nm
[6] Fixing bolt (A) for clamping the machine from the rear side.
The cylinder pins (B) prevent rotation of the fixing bolt.
A
B
[7] Mounting the fixing bolt (B).
B
A
C

Installation Manual ALS 104
01/2016 | 00 19 Installation and Deinstallation
[10] AHead joint element
BJoint axis
Assemble the two halves of the head joint [11A] with
the joint pin [11B] as shown. Tighten the set-screws
at the joint axis.
Slide one half of joint over the trunnion (bolt-on
cylinder) on the machine and tighten the screw
[11A].
– Observe the warning notice (see above). Mount the
head joint assembly with the clamp pointing side-
ways or downwards.
Lift the machine and slide the free end of the head
joint over the end of the support tubing. Tighten the
set-screw [11B].
Tightening torques:
– Set-screws at machine and
stand [11A, B] . . . . . . . . . . . . . . . . . . 45 Nm
– Set-screws at the joint axis [10C] . . . 45 Nm
WARNING!
Danger of injury by the machine falling to
ground.
This danger exists if the machine is to be
mounted so as enable sideways swivel-
ling, i.e. if the pin in the joint is vertical. If
the machine is mounted incorrectly [9], it
will fall to the ground as soon as the set
screws clamping either the top or bottom
half of the joint pin are loosened.
Always mount the head joint assembly
to the machine with the clamp pointing
downwards [8].
Wear safety footwear during mount-
ing.
[8] Correctly mounted head joint assembly. The clamp on the
machine-side of the joint is pointing downwards!
[9] Wrongly mounted head joint assembly. The clamp on the
machine-side of the joint is pointing upwards!
A
A
C
B
C
[11] Assembling the two halves of the head joint (A) with the
joint pin (B).
B
A

Installation Manual ALS 104
01/2016 | 00 20 Installation and Deinstallation
Holding machine in place by side plate or base
plate
– Order number for flange plate assembly [12C] (in-
cluding screws and washers): A7622
Tool:
– 8 mm hexagon socket driver
Screw the flange plate [12C] to the side or base of
the machine.
– Use the four screws provided in delivery (ISO 4762
(DIN 912) M10x25).
Lift the machine and slide the clamp over the end of
the tubing of the support. Tighten the set-screw
[12A].
Tightening torque:
– set-screw [12A] . . . . . . . . . . . . . . . . . 45 Nm
Blind hole depth: 13 mm
[12] Attachment points
B
C
A